Laying and installation method for panels

ABSTRACT

In a method of laying and installing rectangular panels having a first and a second parallel long side ( 701, 702 ) and having a first and a second parallel short side ( 801, 802 ), the panels are installed in parallel panel rows extending along the long sides of the panels. An alignment panel ( 1 ) is coupled to the first long side ( 701 ) of each panel of a first panel row ( 100 ) before a next panel ( 102 ) of the first panel row ( 100 ) is installed.

TECHNICAL FIELD

The present invention relates to a method of laying and installing rectangular panels, in particular, flooring panels.

PRIOR ART

Glueless laying and installation methods for panels (including flooring panels) are generally known in the art. Such panels are often provided on one side with a decor, for example to reproduce the appearance of a real wood panel. This decor can be provided either as a printed paper layer or a veneer, or the decor can be directly printed onto the carrier board. Often, these panels are of rectangular shape and can be coupled to each other using complementary coupling structures which commonly are formed as integral parts at the panel sides. Thus, similar panels can be connected at corresponding adjacent sides to form, for example, a floor or a wall covering. Among these coupling structures in particular various kinds of tongue and groove based coupling structures are known which allow for form fitting connections between similar panels by introducing the tongue of one panel into the groove of another panel. To lock the panels together in horizontal and vertical directions, the coupling structures are further provided with suitable locking elements, which allow the panels to be firmly locked to each other. Thereby it is possible that such tongue and groove coupling structures with additional locking elements can lock respective coupled panels perpendicular to their common connection joint as well as perpendicular and parallel to the panel plane without the need of additional locking means such as glue or nails.

In the case of rectangular panels, it is common that panels are provided with two different kinds of coupling structures, one for the longitudinal or long sides and one for the transversal or short sides. This is often necessary because connection means that work well on a relatively short side (e.g. the transversal side of flooring panels) do not necessarily work well on distinctly longer sides (e.g. the longitudinal sides of flooring panels) and vice versa.

For example, two opposing longitudinal sides of such panels can be provided with tongue and groove coupling structures, which allow similar panels to be connected to each other at adjacent longitudinal sides by angling. Angling in this sense means introducing the tongue of a further panel into the groove of an already installed panel (or vice versa) while the further panel is inclined relative to the laying plane, and then pivoting the further panel by a rotational (“angling”) movement into the laying plane. Often with such systems, the transverse opposing sides of these panels are provided with coupling structures which allow similar panels to be connectable to each other at adjacent transverse sides by vertical folding. Folding in this sense means that the transversal locking means are joined into each other (folded down) by the rotational, scissor-like movement caused by angling around the longitudinal side. This combination of coupling structures allows that a panel can be connected to a row of similar panels by angling this panel along corresponding longitudinal adjacent panel sides, while within the same working step this panel is connected to neighboring panels by vertical folding to corresponding adjacent transverse panel sides. Such panel systems are generally called “angling” and/or “fold down systems”.

Other panel connecting systems have profiles with generally hook shaped profiles, which can be joined by a purely downward movement (as opposed to a rotational movement). Such connecting systems are generally known as “push down systems”. Again other connecting systems have profiles with a tongue and groove system which are designed to lock by a horizontal movement, often necessitating a horizontal knocking action in order to fit the tongue into the groove. As can easily be imagined, there is a multitude of varieties to these connecting systems, which may also be combined by using different systems on the long and on the short sides of the panels.

Panel laying methods known in the art are mostly concerned with optimizing laying and installation according to the specific coupling systems on the long and on the short sides of these panels. For instance, WO0102671A1 and U.S. Pat. No. 6,672,030B2 disclose laying methods for a fold down system aided by wedges. They both teach the laying of a first row as a first step, but not how to align the panels in the first row along the direction of their long sides. EP1462587A1 also teaches to lay a first row of panels first and then to align the second row of panels by a combination of an angling and sliding motion. U.S. Pat. No. 6,546,691B2 teaches to align two panels of a first row by partially angling them into a first panel of the second row with a gap between their short sides and then horizontally displacing the two panels of the first row until the gap is closed, presumably by a knocking action. The document is silent about the manner in which subsequent panels are added.

In prior-art methods, the panels are typically laid row by row, starting with laying a complete first row before a second row is started to be laid. FIGS. 1 and 2 illustrate some alignment difficulties with such prior-art methods. As shown in FIG. 1, in a traditional laying method for flooring panels, panels 101, 102, 103, 104 of a first panel row 100 are laid along a front wall 500 of a room. While the front wall provides for some guidance for the alignment of the first panel row 500, an exact alignment of the long sides of the panels is often impossible. As apparent from FIG. 2, it is then difficult to achieve a secure connection between the long sides of the panels of the first row 100 and the panels of the second row 200. Furthermore, while the alignment of the panels of the second row 200 may be improved as compared to the first row 100, alignment errors from the first row may propagate into the second and subsequent rows. The resulting flooring will have an unsatisfactory appearance and reduced stability.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide a simple and reliable method to lay and install panels, which method ensures that the panels are exactly aligned.

This and other objects which become apparent upon reading the following description, are achieved by a method for laying and installing panels as defined in claim 1.

Thus, a method of laying and installing rectangular panels having a first and a second parallel long side and having a first and a second parallel short side is provided, wherein the panels are installed in parallel panel rows extending along the long sides of the panels. In order to ensure exact alignment of the panels in the first panel row, an alignment panel is coupled to the first long side of each panel of the first panel row before a next panel of the first panel row is installed.

In this manner, the panels of the first row can be exactly aligned with the aid of the alignment panels, and a near to perfect alignment of the panels in the first row can be achieved. After the first row has been laid and aligned with the aid of the alignment panels, at least one further row is added to the ensemble.

In the present context, the term “to couple” is to be understood as meaning that two elements are mechanically joined.

As explained above in connection with the prior art, in order to enable the coupling of adjacent panels and/or alignment panels, the panels and alignment panels will generally comprise, on their first and second long sides, mutually complementary first coupling structures. They will often further comprise, on their first and second short sides, mutually complementary second coupling structures. The first and/or second coupling structures can be integrally formed with the panels. The first and second coupling structures can take any form as known in the prior art. In particular, the first coupling structures can be tongue- and groove-based coupling structures, i.e., the first long side of each panel or alignment panel is provided with a first coupling structure comprising a tongue and the second long side is provided with a second coupling structure comprising a corresponding groove or vice versa. Such tongue- and groove-based coupling structures may be configured to couple panels in adjacent rows, i.e., adjacent panels along the long sides of the panels, by angling. In other embodiments, the first coupling structures can be hook-like structures, which are configured to connect adjacent panels by a vertical push-down movement. The second coupling structures may be configured to couple two adjacent panels in the same row, i.e. adjacent panels along the short sides of the panels, by folding, by a push-down movement, or by introducing an extraneous locking element between such panels. A variety of possible coupling structures are known in the art, and the present invention is not limited to any particular form of first and/or second coupling structures. To lock the panels together perpendicular and parallel to the panel plane, the first and/or second coupling structures may be further provided with integral locking elements, which allow the panels to be firmly locked to each other, or may be complemented by extraneous locking elements. Such locking elements are also well known in the art.

In a first type of embodiments, the alignment panels are provisional alignment panels which are removed after at least a second panel row has been added. In this case, the provisional alignment panels serve only the purpose of aligning the panels of the first row before the second row is added, but are removed again once this goal has been accomplished. While laying provisional alignment panels and subsequently removing them again may seem to be counter-intuitive at first glance, this method provides an easy way to rapidly align the panels and is especially well adapted to let an installer check whether all panel connections are well engaged on all sides before further panel rows are added.

In the first type of embodiments, it is advantageous to avoid coupling the provisional alignment panels to one another at their short sides, i.e., the short sides of each of the provisional alignment panels remain uncoupled to the short sides of any other alignment panel. In this way, removal of the provisional alignment panels is simplified.

In particular, a method of the first type may include the following steps:

-   -   (a) laying a first panel of the first panel row;     -   (b) coupling a first provisional alignment panel to the first         long side of the first panel (in particular, using the first         coupling structures of the first panel and of the first         provisional alignment panel), in such a manner that the first         provisional alignment panel has a portion that extends beyond         the first panel along the first long side;     -   (c) subsequently to step (b), coupling a second panel of the         first panel row to the second short side of the first panel and         to the second long side of the portion of the first provisional         alignment panel that extends beyond the first panel (in         particular, the second panel being coupled to the first         alignment panel by the first coupling structures of the second         panel and of the first alignment panel, and being coupled to the         first panel by the second coupling structures of the first panel         and of the second panel);     -   (d) subsequently to step (c), coupling a further provisional         alignment panel to the first long side of a previously laid         panel of the first panel row (in particular, using the first         coupling structures of the previously laid panel and of the         further provisional alignment panel), the further provisional         alignment panel being coupled to the previously laid panel in         such a manner that the further provisional alignment panel has a         portion that extends beyond the previously laid panel along the         first long side of the previously laid panel;     -   (e) subsequently to step (d), coupling a further panel of the         first panel row both to the second short side of a previously         laid panel of the first panel row and to the second long side of         the portion of the further provisional alignment panel that         extends beyond the previously laid panel (in particular, the         further panel being coupled to the further alignment panel by         the first coupling structures of the further panel and of the         further alignment panel, and being coupled to the previously         laid panel by the second coupling structures of the previously         laid panel and of the further panel);     -   (f) repeating steps (d) and (e) until a desired length of the         first panel row is achieved;     -   (g) installing at least a second panel row adjacent to the first         panel row, each panel of the second panel row being coupled to         the second long side of at least one of the panels of the first         panel row; and     -   (h) removing the provisional alignment panels.

If the panels are floor panels that are installed on a floor of a room having a front wall, the method may further comprise, subsequent to step (h), the following steps in order to ensure that the panels are installed at their correct positions:

-   -   (i) shifting the combined first and second panel rows parallel         to the floor towards the front wall; and     -   (j) installing one or more further panel rows.

In a second type of embodiments, the alignment panels remain coupled to the first panel row, thereby forming panels of a second panel row. In other words, the panels of the first row are directly aligned with the panels of the second row, so that no provisional alignment panels need to be removed subsequently. In this second type of embodiments, the second row is started before the first row is completed, which is again somewhat counter-intuitive.

In the second type of embodiments, it is preferred that the first short side of each further alignment panel is coupled to the second short side of a previous alignment panel using the second coupling structures of the previous alignment panel and of the further alignment panel, so as to create a continuous second row.

In particular, a method of the second type may include the following steps:

-   -   (a) laying a first panel of the first panel row;     -   (b) coupling a first alignment panel to the first long side of         the first panel (in particular, using the first coupling         structures of the first panel and of the first alignment panel)         in such a manner that the first alignment panel has a portion         that extends beyond the first panel along the first long side of         the first panel;     -   (c) subsequently to step (b), coupling a second panel of the         first panel row to the second short side of the first panel and         to the second long side of the portion of the first alignment         panel that extends beyond the first panel (in particular, the         second panel being coupled to the first alignment panel by the         first coupling structures of the second panel and of the first         alignment panel, and being coupled to the first panel by the         second coupling structures of the first panel and of the second         panel);     -   (d) subsequently to step (c), coupling a further alignment panel         to the first long side of a previously laid panel of the first         panel row (in particular, using the first coupling structures of         the previously laid panel and of the further alignment panel)         and to the second short side of a previously laid alignment         panel (in particular, using the second coupling structures of         the previously laid alignment panel and of the further alignment         panel) in such a manner that the further alignment panel has a         portion that extends beyond the previously laid panel in a         direction parallel to the first long side of the previously laid         panel;     -   (e) subsequently to step (d), coupling a further panel of the         first panel row both to the second short side of a previously         laid panel and to the second long side of the portion of the         further alignment panel that extends beyond the previously laid         panel of the first panel row (in particular, the further panel         being coupled to the further alignment panel by the first         coupling structures of the further panel and of the further         alignment panel, and being coupled to the previously laid panel         by the second coupling structures of the previously laid panel         and of the further panel);     -   (f) repeating steps (d) and (e) until a desired length of the         first panel row is achieved;     -   (g) adding a shortened final panel of the second panel row;     -   (h) adding further panel rows.

In particular if the first panel of the first panel row is the same length as the first alignment panel or longer, it may be necessary to install a shortened initial panel of the second panel row before installing the first alignment panel. In this case, the method can further comprise, between steps (a) and (b):

-   -   (a′) coupling a shortened initial panel of a second panel row to         the first long side of the first panel of the first panel row,     -   wherein in step (b) the first alignment panel is further coupled         to the second short side of the initial panel of the second         panel row.

Regardless of the type of embodiment, it is preferred that all panels and all alignment panels have the same coupling structures for coupling the panels and alignment panels to one another.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are described in the following with reference to the drawings, which are for the purpose of illustrating the present preferred embodiments of the invention and not for the purpose of limiting the same. In the drawings:

FIG. 1 shows how misalignments of the panels in a first panel row may result in the prior art;

FIG. 2 shows how misalignments of the panels in the first panel row may propagate as misalignments in further rows in the prior art;

FIG. 3 shows the laying of the first panel of the first row in a first embodiment of the present invention;

FIG. 4 shows the laying of a first provisional alignment panel to the first panel of the first row;

FIG. 5 shows the laying of a second panel of the first row;

FIG. 6 shows the laying of a second alignment panel;

FIG. 7 shows the laying of further alignment panels and further panels of the first row until the first row is completed;

FIG. 8 shows the addition of the second panel row to the first panel row.

FIG. 9 shows the situation after removal of the provisional alignment panels from the first row and a translational movement of the first and second rows to their final position at the front wall;

FIG. 10 shows the addition of a third panel row;

FIG. 11 shows the laying of the first panel of the first row in a second embodiment of the present invention;

FIG. 12 shows the laying of an initial panel of the second row;

FIG. 13 shows the laying of a further panel of the second row, which also serves as an alignment panel for the first row;

FIG. 14 shows the addition of a second panel of the first row and of yet a further panel of the second row;

FIG. 15 shows the situation after completion of the first row, which is fully aligned by panels of the second row;

FIG. 16 shows the situation after completion of both the first and second rows;

FIG. 17 shows the situation after completion of the first, second and third rows.

DESCRIPTION OF PREFERRED EMBODIMENTS

FIGS. 3 to 10 illustrate a method of laying and installing panels according to a first embodiment of the present invention. In this embodiment, the panels of the first row 100 are aligned by provisional alignment panels 1, 2, 3 which will be removed from the first row 100 again, once at least a second row 200 has been added to the first row 100.

FIG. 3 shows the laying of a first panel 101 of the first row 100 according to the present invention. This first panel is laid with an offset 600 from a front wall 500. The length of the offset 600 is at least one width of a panel.

FIG. 4 shows how a first provisional alignment panel 1 is coupled to the first panel 101 of the first row 100. At this stage, portions of a first long side 701 of the first panel 101 of the first row 100 are connected to the second long side 702 of the first provisional alignment panel 1 in such a manner that the first provisional alignment panel 1 extends beyond the first panel 101 of the first row 100 along its first long side 701.

FIG. 5 shows how a second panel 102 of the first row 100 is coupled to the first provisional alignment panel 1 and to the first panel 101 of the first row 100. At this stage, the first provisional alignment panel 1 is connected to portions of the first long sides 701 of both the first 101 and second panel 102 of the first row 100. Because of this, both panels are now perfectly aligned with their first long sides 701 at their short sides 801, 802.

FIG. 6 shows how a second provisional alignment panel 2 is coupled to the second panel 102 of the first row 100. While the first long side 701 of the second panel 102 of the first row 100 and the second provisional alignment panel 2 are now connected, it is preferred that the short sides 801, 802 of the first 1 and second 2 provisional alignment panels are not connected. This will ease the removal of the provisional alignment panels in a subsequent step.

FIG. 7 illustrates the laying of one or more further provisional alignment panels 3 and further panels 103, 104 of the first row until the first row 100 is completed.

FIG. 8 shows the addition of at least a second panel row 200 with panels 201, 202, 203, 204 to the first panel row 100. While it may be desirable for some panel configurations to add a third or even further row(s) at this stage, the installation of more than two rows 100, 200 at this stage generally makes it more difficult to subsequently remove the provisional alignment panels and to bring the now laid rows into their final position.

FIG. 9 shows the situation after the removal of the provisional alignment panels 1, 2, 3 from the first row 100 and a translational movement of the first and at least second rows to their final position at the front wall 500.

FIG. 10 shows the addition of a third panel row 300 with panels 301, 302, 303, 304. The laying of the third and subsequent rows can be done by methods previously known in the art.

The above described method works well for angling systems as described above. With such systems, the provisional alignment panels 1, 2, 3 can simply be slightly angled up and then removed. If the short sides 800 of the provisional alignment panels 1, 2, 3 have not previously been connected with each other, every single alignment panel may be removed individually with ease.

The above described novel method also works well for “push down” systems, however further means or aids such as inserting provisional wedges under the panels of the first row 100 and then tapping down the provisional alignment panels 1, 2, 3 to disconnect them from the panels of the first row 100 may be required to remove the provisional alignment panels 1, 2, 3.

The provisional alignment panels 1, 2, 3 may be specially added panels with specially designed coupling structures on their long sides such that they are readily removable again. However, in preferred embodiments of the above invention, all panels are originally packed as identical panels with identical coupling structures, so that the provisional alignment panels 1, 2, 3 can be reused after their removal from the first row 100 and then be added to subsequent rows.

FIGS. 11 to 17 illustrate a method of laying and installing panels according to a second embodiment of the present invention. In this embodiment, the panels of the first row 100 are aligned by panels of the second row 200. In this second embodiment, no provisional alignment panels will have to be subsequently removed and the first and at least second rows 100, 200 will not have to be moved to a final position.

FIG. 11 shows the laying of a first panel 101 of the first row 100 in the second embodiment. This first panel is laid directly into the starting corner, which is the corner between a side wall 500′, 500″and the front wall 500.

FIG. 12 shows how a shortened initial panel 201 of the second row 200 is coupled to the first long side 701 of the first panel 101 of the first row 100. It should be noted that the roles of the first and second long sides of the panels are now interchanged as compared to the first embodiment. It should further be noted that it is merely a matter of definition which long side is tagged the “first” and “second” long side. These tags do not imply specific coupling structures. In particular, it is well possible that the coupling structures on the first side 701 of the panels in the second embodiment are the same as those on the second side 702 of the panels in the first embodiment.

In the present second embodiment, it is advisable to lay the initial panel 201 of the second row 200 before adding any alignment panel in the second row 200, because nearly all commercially sold connection profiles have generally hook shaped profiles on their short sides, which require the left panel to be laid before the right panel can be engaged. As an example, WO0188306A1, FIGS. 1 to 4 discloses such profiles. The length of this shortened initial panel 201 of the second row 200 may be half the length of a normal panel if a regular pattern (as in FIG. 10) is desired, or an arbitrary length if a seemingly random pattern as in FIG. 17 is desired. The shortened initial panel 201 of the second row 200 can be left away if the first panel 101 of the first row 100 is shortened appropriately before laying.

FIG. 13 shows how a second, unshortened panel 202 of the second row 200 is coupled to the first long side 701 of the first panel 101 of the first row and to the shortened first panel 201 of the second row 200. This panel 202 serves as a first alignment panel for the second panel 102 of the first row 100, as in the first embodiment.

FIG. 14 shows the addition of the second panel 102 of the first row 100 and of the third panel 203 of the second row 200. Panels 101 and 102 are now perfectly aligned on their short sides 800 along their long sides by the aid of the second panel 202 of the second row 200, acting as a first alignment panel. Panels 202 and 203 are perfectly aligned by the second panel 102 of the first row 100.

FIG. 15 illustrates how further panels 103, 104, 204 of the first 100 and second row 200 are added, until the first row 100 is completed.

FIG. 16 shows the completion of the second row 200 by a shortened final panel 205 of the second row 200.

FIG. 17 shows the addition of one or more further rows 300 with panels 301, 302, 303, 304, 305 to the second row 200. No further alignment measures are now needed, since rows 100 and 200 are already perfectly aligned.

It is to be understood that the present invention is not limited to the exact numbers of panels shown in the rows of the figures described above, but is applicable for any number of panels to be aligned and to be laid.

It should further be understood that the present invention can also be executed if the laying is started in any other corner of a room if the panels have suitable connection profiles, and that the present invention is not limited to the laying of floor panels, but can also be employed for the laying of wall panels.

LIST OF REFERENCE SIGNS

-   1 First provisional alignment panel -   2 Second provisional alignment panel -   3 Third provisional alignment panel -   100 First panel row -   101 First panel of first row -   102 Second panel of first row -   103 Third panel of first row -   104 Fourth panel of first row -   200 Second panel row -   201 Shortened initial (first) panel of second row -   202 Second panel of second row -   203 Third panel of second row -   204 Fourth panel of second row -   205 Shortened final panel of second row -   300 Third panel row -   301 First panel of third row -   302 Second panel of third row -   303 Third panel of third row -   304 Fourth panel of third row -   305 Fifth panel of third row -   500 Front wall -   500′ Side wall -   500″ Side wall -   600 Offset from front wall -   701 First long side of a panel -   702 Second long side of a panel -   801 First short side of a panel -   802 Second short side of a panel 

1. A method of laying and installing rectangular panels having a first and a second parallel long side and having a first and a second parallel short side, the panels being installed in parallel panel rows extending along the long sides of the panels, wherein an alignment panel is coupled to the first long side of each panel of a first panel row before a next panel of the first panel row is installed.
 2. The method of claim 1, wherein the alignment panels are provisional alignment panels, the method comprising removing the provisional alignment panels after at least a second panel row has been added.
 3. The method of claim 2, wherein the short sides of each of the provisional alignment panels remain uncoupled to the short sides of any other provisional alignment panel.
 4. The method of claim 1, the method comprising the following steps: (a) laying a first panel of the first panel row; (b) coupling a first provisional alignment panel to the first long side of the first panel in such a manner that the first provisional alignment panel has a portion that extends beyond the first panel along its first long side; (c) subsequently to step (b), coupling a second panel of the first panel row both to the second short side of the first panel and to the second long side of the portion of the first provisional alignment panel that extends beyond the first panel, (d) subsequently to step (c), coupling a further provisional alignment panel to the first long side of a previously laid panel of the first panel row in such a manner that the further provisional alignment panel has a portion that extends beyond the previously laid panel along the first long side of the previously laid panel; (e) subsequently to step (d), coupling a further panel of the first panel row both to the second short side of a previously laid panel of the first panel row and to the first long side of the portion of the further provisional alignment panel that extends beyond the previously laid panel; (f) repeating steps (d) and (e) until a desired length of the first panel row is achieved; (g) installing at least a second panel row adjacent to the first panel row, each panel of the second panel row being coupled to the second long side of at least one of the panels of the first panel row; and (h) removing the provisional alignment panels.
 5. The method of claim 4, wherein the panels are floor panels that are installed on a floor of a room having a front wall, the method further comprising, subsequent to step (h), the following steps: (i) shifting the combined first and second panel rows parallel to the floor towards the front wall; and (j) installing one or more further panel rows.
 6. The method of claim 1, wherein the alignment panels remain coupled to the first panel row, thereby forming panels of a second panel row.
 7. The method of claim 6, wherein the first short side of each further alignment panel is coupled to the second short side of a previous alignment panel.
 8. The method of claim 6, comprising the following steps: (a) laying a first panel of the first panel row; (b) coupling a first alignment panel to the first long side of the first panel of the first panel row in such a manner that the first alignment panel has a portion that extends beyond the first panel along the first long side of the first pane; (c) subsequently to step (b), coupling a second panel of the first panel row to the second short side of the first panel and to the second long side of the portion of the first alignment panel that extends beyond the first panel; (d) subsequently to step (c), coupling a further alignment panel both to the first long side of a previously laid panel of the first panel row and to the second short side of a previously laid alignment panel in such a manner that the further alignment panel has a portion that extends beyond the previously laid panel of the first panel row in a direction parallel to the first long side of the previously laid panel; (e) subsequently to step (d), coupling a further panel of the first row both to the second short side of a previously laid panel of the first row and to the second long side of the portion of the further alignment panel that extends beyond the previously laid panel of the first row; (f) repeating steps (d) and (e) until a desired length of the first panel row is achieved; (g) adding a shortened final panel of the second panel row; (h) adding further panel rows.
 9. The method of claim 8, further comprising, between steps (a) and (b): (a′) coupling a shortened initial panel of a second panel row to the first long side of the first panel of the first panel row, wherein in step (b) the first alignment panel is further coupled to the second short side of the initial panel of the second panel row.
 10. The method of claim 1, wherein all panels and all alignment panels have identical coupling structures for coupling the panels and alignment panels to one another. 